OCC bales
Photo courtesy CP Group

Exceeding purity standards

How an upgraded system from CP Group used an engineering solution to surpass requirements.

November 1, 2021

Cal-Waste partnered with CP Group to install a 30-ton-per-hour system upgrade to meet updated quality standards and throughput demand. CP Group combined layout design, its latest screening technology and near-infrared (NIR) diffused optical separation. 

The MRF was an investment to better serve Cal-Waste's communities and municipalities. It also helps provide material buyers higher grade commodities, create a robust material outlet for haulers, process more material and provide workers a safer environment. The results of this engineered solution for the 30-ton-per-hour MRF showed an increase in processing capacity of 173 percent while only increasing manual sorting headcount by 29 percent. 

Fractionate for safety 

Positioned before the presort conveyor, the Primary Auger Screen increases the overall processing capacity and performance of the MRF by fractionating the material stream. The screen’s unders fraction has an 8-inch hole sizing that reduces material volume from the presort conveyor by 50 percent. 

The larger materials go in the overs fraction that is then presented to the presort station. This results in more efficient manual sorting by reducing the overall system headcount and increasing safety and productivity. 

The Secondary Auger Screen has a 5-inch hole opening that removes single-serve containers from larger fiber materials. This results in a cleaner fiber end product. 

Liberate for purity 

The CP Glass Breaker Screen uses cast-chromium alloy discs for minimal wear and tear while providing high removal of glass and fines. The old corrugated containers (OCC) screen operates with low-maintenance steel discs that have a long wear life and provide efficient removal of OCC. 

Both the CPScreen and the CP Anti-Wrap Screen use patented disc designs to liberate 2D materials from 3D while maximizing fiber capture rates and end-product quality. By agitating materials with our high amplitude disc screens, glass, dirt and fines are liberated from the commodities and captured by the third cut on the CP Screen. 

These screens have unmatched disc longevity. The CPScreen has a wear life of up to two years of operation, and CP Anti-Wrap Screen discs can last more than three years before requiring replacement. 

Separate for efficiency  

In the past, Cal-Waste had manual sorting on both fiber and container commodities. Now the facility separates with five automated optical sorters. Selective separation is a cornerstone of MRF design that yields an increase in overall system intelligence and value. There are three MSS CIRRUS FiberMax high-volume optical sorters with belt speeds processing at 1,000 feet per minute and the capability of 1,000 picks per minute. These optical sorters help Cal-Waste achieve its fiber purity goals while maximizing throughput and minimizing manual sorting headcount. 

Additionally, two MSS CIRRUS PlasticMax optical sorters recover polyethylene terephthalate (PET), high-density polyethylene (HDPE) and mixed plastics with minimal manual sorting by using NIR technology to separate various grades of plastic containers.  

And finally, the CP Lights Out is an air drum separator for glass processing that carries clean material to an automated glass self-load-out system. 

The result

Performance testing results for this MRF showed system availability of 95 percent. The mechanical capture rate and optical removal efficiencies surpassed the customer’s end-product purity needs in every category. The Cal-Waste facility upgrade was an investment in new technology, automation and innovative design to produce high-quality commodities that are exceeding market requirements. 

Learn more about engineered solutions here.